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:._ REPRODUC!BIL.ITYOF Tl-t.lf_-...O.R!GIr,I.ALPAGE '5......POOR,_ _.

1974023215

https://ntrs.nasa.gov/search.jsp?R=19740023215 2020-03-27T05:57:40+00:00Z

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LMSC-D383059Vol I

REUSABLE AGENA STUDY

FINAL REPORT

EXECUTIVE SUMMARY iq

Prepared for

NationalAeronauticsand Space Administration,Marshall Space FlightCenter,

Huntsville,Alabama

ContractNo. NAS8-29952

LOCKHEED MISSILES & SPACE COMPANY

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FOREWORD

This final report of the Reusable Agena Study was prepared for the National

Aeronautics and Space Administration George C. Marshall Space Flight Center

by Lockheed Missiles & Space Company, Inc., in accordance with Contract

NAS8-29952.

The study effo_ described herein was conducted under the direction of National

Aeronautics and ,_pace Administration Study Manager, Mr. James B. Brewer.

The report was prepared by the Lockheed Missiles & Space Company, Inc., Sunnyvale,

California under the direction of Mr. Warren K. Carter, LMSC Study Manager, assisted

by Mr. W. Mimnaugh, Mr. D. A. Douglass, Mr. J. E. Piper, Mr. C. V. Hopkins and

Mr. S. S. Sagawa. The study results were developed durir.g the period from June

1973, through November 1973, and the final report was distributed in January 1974.

This reportconsistsoftwo volumes:

Volume I Executive Summary

Volume II Technical Report

References have been made as appropriate to the more detailed data contained in the

Data Dump documentation furnished to the National Aeronautics and Space Administra-

tion on September 25, 1973.

Requests for additional information should be addressed to:

Mr. James B. Brewer

Manager, Initial Upper Stage StudiesSpaoe Tug Task Team, PD-TugMarshall Space Flight CenterMarshall Spaoe Flight Center, Alabama 35812

Telephone: (205) 453-2795

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CONTENTS

Section Page

FOREWORD ii

I INTRODUCTION i-I

2 STUDY OBJECTIVES 2-1

3 RELATIONSHIP TO OTHER NASA EFFORTS 3-1

4 METHOD OF APPROACH AND PRINCIPAL ASSUMPTIONS 4-I

5 BASIC DATA GENERATED AND SIGNIFICANT RESULTS 5-I

5.1 Shuttle Interface 5-2

5.2 Performance 5-7

5.3 Safety 5-11

5.4 Operations 5-12

5.5 Special Mission Considerations 5-12

5.6 Cost 5-12

5.7 Alternative Concepts 5-19

6 CONC LUSIO NS 6-i

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ILLUSTRATIONS

Figure Page

1-1 Agena Improvement Since 1970 1-2

1-2 Building Block Concept 1-3

3-1 Shuttle/Agens Background 3- 1

5-1 Shuttle/Agena Upper Stage 5-1

5-2 BAC 8096 Engine Modifications 5-3

5-3 Nominal/Augmentation Comparison 5-3

5-4 Nominal System Weight Summary 5-4

5-5 Augmented System Weight Summary 5-5

5-6 Cargo Bay Support Structure, Side View 5-5

5-7 Cargo Bay Support Structure, Forward View 5-6

5-8 CBSS Conversion Kit 5-7

5-9 Nominal Shuttle/Agena Upper Stage Performance 5-8

5-10 Augmented Shuttle/Agena Upper Stage Performance 5-9

5-11 Agena Building Block Performance 5-10

5-12 Shuttle/Agena Upper Stage Performance - Reusable Mode 5-10

5-13 Shuttle/Agena Upper Stage Mission Profile 5-13

5-14 Flight-to-Flight Operations 5-13

5-15 Servicing Mission Profile 5-15

5-16 Payload Envelopes 5-15

5-17 Funding Requirements 5-18

5-18 Growth Agena Concept/Drop Tank Agens Concept 5-20

5-19 Alternative Concepts Characteristics/Comparison 5-22

5-20 Drop Tank and Growth Agena Weight Concepts 5-23

5-21 Synchronous-Equatorial Payload Capability for N204/MMHConfigurations Isp = 326 Sec 5-23

5-22 Growth Agena Performance 5-24

5-23 Drop Tank Agena Performance 5-25

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SectionI

INTRODUCTION

The Shuttle Agena Upper Stage interim tug concept which is emphasized in this

summary report is based on a building block approach. These building block

concepts are extensions of existing ascent Agena configurations.

Several current improvements, incorporated or in development since 1970,

have been used in developing the Shuttle/Agena Upper Stage concepts (Fig. 1-1).

High-density acid (HDA) is used as the Agena Upper Stage oxidizer. The baffled

injector is used in the main engine. The DF-224 is a fourth generation computer

currently in development and will be flight proven in the near future.

The Agena Upper Stage building block concept (Fig. 1-2) uses the current Agena a,_

baseline, adds an 8.5-inch {21.6 cm) extension to the fuel tank for optimum mixture

ratio, uses monomethyl hydrazlne (MMH) as fuel, exchanges a 150:1 nozzle extension

for the existing 45:1, exchanges an Autonetles DF-224 for the existing Honeywell

computer, and adds a star sensor for guidance update. These modifications to the

current Agena provide a 5-foot (1.52 m) diameter Shuttle/Agena Upper Stage that will

fly all Vandenberg Air Force Base (VAFB) missions in the reusable mode without

resorting to a kick motor.

The A velocityof theAgena isincreasedby use of a strap-onpropellanttank (SOT)

option. This optionprovidesa Shuttle/AgenaUpper Stagewiththe capabilitytoplace

almost 3900 pounds (1769kg) intogeosynehronousorbit(24hour period)withoutthe

aidofkick motors.

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The baseline Agena Upper Stage building block concept depicted in Fig. 1-2 is available

in two configurations, Nominal and Augmented. The two ccmigurations are identical

except in thc avionics area and in the 5-foot diameter Agena core tank material. The

Shuttle interface, including the cargo bay support structure, is the same for both

configurations. The configuration recommended as a candidate interim Space Tug is

the Nominal configuration, This recommended Nominal configuration is emphasized

in both this summary report and in the detailed technical report.

AGENAOPERATIONALPROGRAMS

i /

" HDA

1970" ACS ACQUISI974_.. INJ MMH _ --_COMI

LMSCIR&D& OTttERPROGRAMS

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• FIRSTFLIGHT

Fig. I-i Agena Improvements Since 1970

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CURRENTAGENA BASELINEUPPER-STAGE

• FUELTANK '_,:.-....

" \ I\ L 2_,n -" I20.7FT ', " _._I_ I_ M_,_II -.,_ IL93m)--- ------I16.31ml "_,'_"•::" • 150:1NOZZLE

!_ [XTENSION

_'_._;_ • DF'.?24 / STRAP-ON-TANK(SOT)OPTION

'_':'-"'" ----IJ COMPUTER_l,_/II

J'i:i'_"II • STARSENSOR

. ,,.._._

17.93m) m

Fig. 1-2 Building Block Concept

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Section2

STUDY OBJECTIVES

ThF. specific objective of tl'is Reusable Agena Study was to establish a Shuttle/Agena

Upper Stage concept as an interim Space Tug that meets, or exceeds, NASA and DoD

mission requirements. Several key issues were addressed in meeting this objective.

These issues included:

• Feasibility of building block concept • Safety

• Special mission flexibility • Low cost

• Mission model capture • Expendable booster transition

• Performance • Grozth

• ETR versus WTR

The building block concepts presented in this report are attractive and feasible

approaches to a Shuttle Upper Stage. These concepts exhibit the flexibility needed to

meet the requirements of special missions such as on-orbit spacecraft servicing,

and for special payloads as lcng as 40 feet. One hundred precent mission capture is

achieved for two entirely different mission assignments of (1) assuming both KSC and

VAFB are operational, and (2) assuming all missions are flown from KSC.

Another important issue concerns the period of transition from expendable boosters

to use of the Shuttle. It seems highly desirable that the Shuttle Upper Stage be easily

adaptable, with minimum modification, to either Shuttle or conventional booster

launches during this transition period.

Equally important is the capability for further growth within the bounds of existing

technology. Since mission modvls tend to change, and payloads always seem to increase

in weight, the building block concept should permit growth to higher levels of per-

formance without unreasonable penalties in cost, risk, or schedule.

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Section 3

RELATIONSHIP TO OTHER NASA EFFORTS

The original Shuttle/Agena Compatibility Study was initiatedin 1971. (Fig. 3-1)

This study involved definitionof the required expendable Agena modifications for

compatibilitywith the Space Shuttle,and preliminary design of the required cargo

bay interfacesupport equipment. The Shuttle/Agena Compatibility Study follow-on,

performed for Lewis Research Center during 1973, continued the curlier work for

an expendable Agena.

L AGENAOPERATIONALIMPROVEMENTSSHUTTL!COMPATIBILITY

STUDYNASq-l1949JSC

AGENAUPPER LMSC

COMPATIBILITY STAGE EVOLUTIONARYSllJOYFOLLOW-ON CONCEPTS CONCEPT

NAS3-16787

REUSABLEAGENASTUOYNAS8-29952

MSFC4"X

L&_SCI_D[PEND[NTDEVELOPMEkrTPROGRAMS&OTHERPROGRAMS -_

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Fig. 3-1 Shuttle/Agen_ Background

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Section 4

METIIOD OF APPI{C)ACH AND PRINCIPAL ASSUMPTIONS :

A b_dlding block concept of a Reusable Agena was selected with consideration of

mission performance, low DDT&E cost, low operating cost, low risk, high reliability,

a_d safety. Shuttle/Agena Upper Stage missions will consist of payload delivery

followed by stage-only recovery. Maximum use of hardware that is flight-proven or

under development was made to minimize risk and to keep DDT&E costs low.

'['hc following key guidelines are applicable to the study:

• M,'tximum use will be made of components in existence or under development.

• The mission accomplishment reliability goal is 0.97.

• Performance figures reflect a 10-percent across-the-board weightcontingency allowance for the 10-foot diameter and drop tank Agenas.

• Performance figures for the Nominal and Augmented Shuttle/AgenaUpper Stage reflect a combined 2 percent contingency on existinghardware and a 10-percent contingency on new or modified hardware.

• A ].7-percent flight performance reserve applies to the 10-footdiameter a_! drop tank Agenas.

• A t-percent flight performance reserve with an added 50 lb fuel biasapplies to the Nominal and Augmented Shuttle/Agena Upper Stageconcepts.

• The communications system will be fail operational/fail safe.

• The minimum synchronous equatorial payload capability for payloaddelivery and return of the empty Agcna is 3500 pounds (15S7.6 kg).

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Section 5

BASIC DATA GENERATED AND SIGNIFICANT I{E_U L'I',5

The Shuttle/Agcna Upper Stage concept depicted in Fig. 5-1, meets or exceeds

all requirements for an interim Space Tug. This Agone Upper Stage concept utilizes

high-density acid (44 percent N204) and monomethyl hydrazine (MMH) as propellants.

The main engine is a Bell 8096I, with a 150:1 nozzle expansion ratio giving an Isp of

324 seconds (31_0 N sec/Kg). It has a total main propellant load, inch_ding the optmnal

strap-on tanks ._OTs), of approx_.mately 56,000 pounds (25400 kg). It hits a hydrazine,

monopropellant hot-gas attitude control system and features a fourth generation

Autonetics DF-224 computer.

All vehicle equipment, excopt for the optional SOT feature and minor engine modifications,

is either existing and flight proven or is in development with a iirst-flight date scheduled

for no later than 1976.

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Fig. 5-1 ShuttlelAgena Upper Stage

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The lltght-proven Bell 8096 rocket engine will be modified, as illustrated in Fig. 5-2.

These minor modifications a"e needed to permit engine restart beyond the existing

three-start capability, to permit hot-pump restart with no time constraints, to in-

crea_.e Isp, and to operate the gas generator at the optimum mLxture for the IIDA/MM]!propellant combination.

Fwo avionics concepts have been established for the Shuttle/Agena Upper Stage concept.

A comparison between the r vo is presented in Fig. 5-3. rhe Nominal concept ts

basically a single-string guidance and data management system with backup stabiliza-

tion electronics for emergency stabilization of the Agena during the on-orbit retrieval

operation. The Augmented concept is a dual-string guidance and data management

J system. The backup retrieval stabilization electronics is not needed in the Augmentedconcept because one of the dual IMUs furnishes this function

l

As can be seen from Fig. 5-3, the Augmented Agena Upper Stage concept is 85 pounds

(38.6 kg) heavier and has a higher mission accomplishment reliability figure. Thc syn-

chronous equatorial injection accuracy for each concept meets the study requirements,

with the horizon sensor on the Augmented concept providing increased injection accuracy.

A more detailed weight statement for the Nominal and Augmented concepts are presented

in Fig. 5-4 and 5-5.

5.1 SHUTTLE INTERFACE

The primary Shuttle interface item tt the cargo bay support structure (CBSS) Since

both the Nominal and Augmented 8huttle/Agena Upper Stage concepts fly either with

the SOT option or as a core vehicle alone, the CBSS mast accommodate both configura-

tions. Figure 5-6 presents a CBSS concept for use with the SOT ot.tion. It consists

of a welded, tubular aluminum truss frame in two parts: the forward section transfers

only lateral loads to the cargo bay attach points, while the aft section transfers lateral

and longitudinal loads. The Agena is secured in the CBSS by two pinned attachments

at the forward end of the Agena and by a hinged clamp-tv3x- i. _h t:mt mates with a

eircumfe:'ential V-ring located on the outer periphery of ,t:_- _: _,O'1'support structure.

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NOMINAL AUGMENTED

DUALHIGHMOD[THRUSTERS' DUALHIGH'+ SINGLELOWMODETHRUSTER',

QUADOMNIANTENNAS+ AMPLIFIER DUALPARABOLIC+ QUADOMNI ANTENNAS

PRIMARYBATTERYTYPE30+ TYPEIVB PRIMARYBATTERYTYPE19C2+ 2 TYPEIVB(BACKUP1TYPEIVB) (BACKUP1TYPEIVB)

BALLBROS.STARTRACKERS BENnlXSTARTRACKER

SINGLEHONEYWELLIMU DUALHONEYW[IL IMU

QUANTIC HORIZONSLNSOR

SINGLESTRINGDF'224COMPUTER DUALSTRINGDF224COMPUTER

BACKUPRETRIEVALACS ELECTRONICSTAPERECORDER

WEIGHT 2,912 LB WEIGHT3,051RELIABILITY.974 RELIABILITY.980

ACCURACY (:)SIGMA) ACCURACY (]SIGMA}

TANG, 116NM (216kin) TANG. It6NM (216kin)NORM, 6NM(llkm) NORM. 6NM(llkm)RAD. 60NM (Ill kin) RA']. 60 NM (Ill kin)

Fig. 5-3 Nominal/Augmentation Comparison

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Core Only Core With SOT ]Subsystem Ib (kg) Ib (kg)

Structure 610 1,2 95

Propulsion 568 768

Avionics

Electrical 234 239

Guidance/Navigation 127 12 7

Data Management 149 166

Communications 85 85

Thermal 27 57

Contingency (2 %/10 %) 83 175

Dry Weight 1,883 (854) 2,912 (1,321)

Nonusable Residuals 74' 203"

Propellant Reserves (1% FPR) 52 83

Burnout Weight 2,009 (911) 3,198 (1,451)

Usable Propellants 14,765 55,516

Usable ACPS Propellant 40 54

StartStop Losses 129 218

IgnitionWeight 16,943(7,685) 58,986(26,756)

Suppor_Equipment i,636 (742) I,536(697)

Total Installed Weight W/O Payload 18,579 (8,427) 60,522 (27,453)

Fig. 5-4 Nominal System Weight Summaryp

(*Includes 50 lb fuel bias)

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Core Only Core With SOT

Subsystem lb (kg) lb (kg)

Structure 567 1,252

Propulsion 574 774Avionics

Electrical 217 276

Guidance/Navigation 222 222Data Management 149 166Communications 106 106

Thermal 27 57

Contingency (2',;_�lOS}';) 107 198

Dry Weight 1,969(893) 3.t 051(1384)Nonusable Residuals 74" 203*

Propellant Reserves (1_;[.FPR) 52 83

2,095(950) 3,337(1514)

Burnout WeightUsable Propellants 14, 718 55,516Usable ACPS Propellant 43 54Start Stop Losses 176 218

Ignition Weight 17,032(7,726) 59,125(26,819)

,Support Equipment 1,638(742) 1,536(697)

Total Installed Weight W/O Payload 18p668(8,468) 60,661(27,516)

Fig. 5-5 Augmented System Weight Summary

(*Includes 50 lb fuel bias)

(SOTOPTION)

"--59 IN._ FI8 IN.

4 iT.5m)4 L/(0.5/m),.., STAl )N.--------_ - %,.j_ I__.04m,ST,Z f i",J

" "I -.......FORWARD _.,. I....

SECTION_ _t, ; ._

ELECTRICAL "-- 60 IN. "_"UMBILICAL (l.SZm}RETRACTOR

Fig. 5-6 Cargo Bay Support Structure, Side View

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Ager, a deployment (l.'ig. 5-7) requires only retraction of the propellant emergency

dLlmp and electric'd umbilical connectors, attachment of the Shuttle-attached manipulator,

and opening of the segmented clamshell doors. The Agena and attached payload can

then be lifted straight up out of its support structure and the cargo bay for deployment.

_llen the reusable mission A velocity is compatible with the 5-foot (1.52 m) diameter

core vehicle (no SOT option), a CBSS conversion kit is used (Fig. 5-8). The deploy-

meat sequence is exactly the same as with the SOT option CBSS.

l.'or payloads in the 10,000 to 20,000 pound (4500 to 9100 kg) class, the CBSS requires

minor strengthening. The corresponding CBSS weight penalty, even for a 20,000 pound

payload, is only 67 pounds (30.4 kg).

(SOTOPTION)+Z LATCH.2 PLACES

/ \ ',\/

<, ,)\\ /

'\ //HINGE,4 PLACES

Ii J--'Y:)-SEGMENTCORRUGATEDSHELL

FUELOUMPLINE OXIDIZERDUMPLINE

PROPELLANT ,.LINE REIRACTOR _ /

Fig. 5-7 Cargo Bay Support Structure, Forward View

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LATCH.3 PLACES,Z

61.5 MENTCLAMSHELL CORRUGATEOSHELLACTUATOR FITTING,Z 4 PIACES

5.5

(}PLACES __il .___i./_...(_,_," iO_B_pORI.,0N

SHELLSUPPORT ', "'_-.STRUCTURE k...

-Z

(AGENACORESTAGE)(VIEWLOOKINGFORWARD)

Fig. 5-8 CBSS Conversion Kit

The only other major Shuttle interface equipment item is the Agena service panel.

This panel is the avionics, control, and caution/warning display interface with the

Agena. This pav_ could be located in the Mission Specialist console. It performs

Agena health checks, conducts the Agena predeployment check, controls Agena-related

deployment and retrieval functions, controls emergency dump, and contains caution

and warning displays. These functions are performed without support from the Shuttle

avionics or data management systems except for electrical power and a tie-in with

the Shuttle communication system for downlink transmittal of Agena data.

5.2 PERFOR:iANCE

The 5 foot (I. 52 m) diameter core Agena can accomplish all Western Test Range (WTR)

assigned missions in the reusable mode without the SOT propellant option and without

,ile use of a kick motor. Both the Nominal and Augmented configurations have this

capability (F_g. 5-9 and 5-10). The Agerm Upper Stage with the SOT option caa

accomplish ;tll Eastern Test Range (ETR) and WTR launches for the 1980-1983

missio_l model in the reusable mode (except for two flights in one interplanetary

i _ission) without the use of a kick motor.

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The Nominal Agena Upper Stage {single-string avionics) performance is presented in

Fig. 5-11 as a function of the Agena building block approach.

(SYNCHRONOUSEQUAIORIAU

EXPENDABLE\ REbSABLE\324otb\ - \

4515LB \ 2885LB \

13,380LB \ 3,895LB \

.L_ (6069I_) _67 kg) _13,11o'CB\ IO.930LS\

"LIMITEDBYSHUTTLEPAYLOADCAPABILIIY

Fig. 5-11 Agena Building Block Performance

A summary table of both the Nominal and Augmented Agena performance is presented

in Fig. 5-12.

Nominal lb (Kg) Augmented lb (Kg)

Configuration 2%/10% 10% 2%/10% 10%ConUngency Contingency Contingency Contingency

ml

5 Ft Dla Core 28 85 2710 2870 2700Plus Optimum KickMotor 1(1309) ,0225), (13_) 0225)

Core Plus Strap 3895 3362 3560 2980On-Tank PropellantOption ((1767) 0525) (1615) (1352)

Core Plus Strap.OnTank Propellant 10930 10838 10763 10610Option Plus (49_) (4916) (4882), (4813)OpUmum Kick Motor

Fig. 5-12 Shuttle/Agena Upper Stage Performance-Reusable Mode

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5.3 SAFETY

There are three prime considerations of concern for Agena Upper Stage safety, as

follows:

• Positive propellant tank pressure control (redundant automatic, astronautoverride)

• Positive propellant dump (on pad, during asceQt, and on orbit)

• Fail operational/fail safe during orbital retrieval (redundant communications,redundant attitude control system, and astronaut override by RF command)

One of the safety concerns is the integral bulkhead of the Agena main propellant tank.

A number of safeguards and backups have been provided for both nominal as well as

emergency conditions. Individual, dedicated pressure regulators are provided to

maintain a positive pressure across the bulkhead under nominal operating and emergency

dump conditions. The computer located in the Agena service panel automatically

monitors oxidizer and fuel tank pressures for both the main and SOT tanks and controls

pressurization line shutoff valves and tank vent valves. The tank vent valves are quad

redundant. The astronaut at the mission specialist console can manually override any

or all of the computer controlled valves as desired. As a final backup, the emergency

dump system can be used to control tank pressures.

The Agena emergency propellant dump system will accomplish a full propellant dump on

pad, during ascent, and on orbit. During ascent, Agena dump is accomplished during

the Shuttle main engine burn portion of the return-to-launch site trajectory. On-orbit

the jet impulse of the existing propellant will impart sufficient impulse to the Shuttle

to settle the Agena propellants for dump.

Fail operational/fail safe capability is provided for critical Agena functions during the

retrieval operation. A fully-redundant communications system is provided for use as

a backup if astronaut override of Agena functions is needed. A backup, redundant

attitude control system is also provided and includes a dedicated battery power supply,

hydrazine tank, and guidance electronics. Both the Nominal and Augmented Agena Upper

Stage concepts provide redundant hot-gas attitude control thrusters.

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5.4 OPERATIONS

The Agena mission profile for tbe reusable mode, Fig. 5-11, includes return of the

Agena to the Shuttle orbit, its retrieval, followed by return to earth for maintenance

and refurbishment for reuse. Agena flight-to-flight operations, Fig. 5-12, are paced

by Shuttle servicing spans and require a total of 340 hours. Payload mating can be

accomplished with the Agena either in the horizontal or vertical position. Loading pro-

pellants and gases can take place either at an on-pad or remote facility. Although it

s-_ems more desirable to load the Agena with propellants and gases prior to Shuttle mate,

the Agena could be loaded within the cargo bay but with added Shuttle interface

complications.

5.5 SPECIAL MISSION CONSIDERATIONS

A servicing mission involves the replacement of expended components on four widely

separated spacecraft at synchronous equatorial positions, as shown in Fig. 5-13. This

figure presents a typical mission profile for a servicing mission accomplished by the

Agena Upper Stage core vehicle (no SOT option) with 351 pounds (159 kg) of rendezvous

equipment and a 300 pound (136 kg) servicing module containing 1800 pounds (815 kg)

of replacement components. The Agena rendezvous with each spacecraft in turn, and

replaces 450 pounds (204 kg) of components at each spacecraft. The mission requires

twelve days to accomplish, including phasing time between spacecraft.

The same mission can be flown in the reusable mode using the SOT propellant option.

! tlere the Agena can replace 903 pounds (410 kg) of components at each spacecraft as

_ shown in the tabulation below. This mission requires an extra day (total of 13) to permit

time for the Agena to return to the Shuttle orbit for retrieval.

SERVICING MISSION

(SYN EQ- 300 lb (136 kg) requirement}

Expendable- 12 Da_,s Reusab!e- 13 Days

_BaselineIb k_ Ib k_

Satell'tu No. 1 _ "_'5;[ Satellite No. 1 _Satellite No. 2 450 204 Satellite No. 2 903 410Satellite No. 3 450 204 Satellite No. 3 903 410Satellite No. 4 450 204 Satellite No. 3 903 410

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.... • _'_'_'..._ I _ _,'-_i .:.,- ,_, J_ _ II ,,,_ _ I ,',._..,I.':..__.-_: '_¢" I'I'_"_ I I':_'_STA_,NOl_,J °"'''N''"'°N L__",_.t-., '--"-_'V"I ,_;,',' _ _| : -'-. _ _ . ..... \ KLTUIIN_

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/11111.1I II,,_ilN,o__% " _.oil.,,I,_,_.f l_,'fJ'T"/ __'_"_I _-"---; :,-L.,v-__: r_I_I!\I k. ---- _NTil_'ANO!",_ I .-

"_ IIlP_ TEIlMINALPHASEI _,. _" '- .- lj

L_-LLJ_ i'''°"'''''N'I "HOI_IIUHIAL IJIIE_DtNG

Fig. 5-13 Shu,'tle/Agena Upper Stage Mission Profile

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The Agena Upper Stageisapproximately26 feet(7.93m') in length.The Agena can

handlepayloadsas longas 40 feet(12.2m) by theapproach illustratedin Fig. 5-14.

The nozzleextensionlengthcan be reduced by approximately6 feet(1.83m) by utilizing

a convolutednozzlethatis extendedtoa 80:1expansionratioafterAgena deployment

in orbit.

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AGENARECIRCULARIZES

ATSAT.NO. ) _ _ 1500....... -,. /--AGENA INITIATESPHASE

'k SERVICES_ /j,"_'-_-"_'_i'_ / ORBITTOSAT.NO. 3_kl. NO. 3 " /

• _LUI_J4NB_, /_7_ " I\ /SAT.NO 2

P_IA_EORBITAND T "_" /" ,,r".C"-, ', "i( 1R,c,_r_LA_,ZES//]kf ( _l':ic "_ 1-'o• ' "" ' _" - --.."- - 1 _ , J ! 3.Sv._AGENAPERFORMSATSAT.P'_O.4 --'__ i \ _.._,Z_,"_ I'l s'''- PHASEORBITA/_D

,_ ,_,, _"k. :"' / _ m_ RECIRCULARIZESATq--A,,ENAPERFO_,-:, ira!-4 "_.... "' SYNCHRONOUS .. _t_,_'---- AC;:7:;.' L,V;{CES j_"_@_ SAT. NO.2

I I-" SHUTTLEDELIVERS '_._ ° ,:_LO ,Ltm_/ SAT.NO.1I |AGENA INTOINITIAL_. _ +/ AW.450LB(204kgl/ _ PHASEORBIT _ |35O

[r _ ,/ / PLANECHANGE

_.y ANDCIRCUIARIZATION_-':'--_.'." ATSCNCHRONOUSEQUATORIALALTITUDE

Fig. 5-15 Servicing Mission Profile

SHUTTLECARGOBAY

' SOT lI _ OPTION

ENVELOPE (4.58m)

- M FTIlO.)7 m} =!- --26 FT17.93m)_

--II sc:I

ENVEIOP[ (4.5,_m)

I L----.Y"co.v II NOZZa,i ii i .m,. ,,

_-- 40.]n IIZ.Z3m) =r!:-19.9 FI16.07m)-.,J

Fig. 5-16 Payload Envelopes

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5.6 COST

The Shuttle/Agena Upper Stage system features low cost over itsentire life cycle-

from DDT&E through the Production phase and through four calendar years of Opera-

Lions. The life cycle costs may be summarized as follows:

DDT&E Pro- Opera- Totalduc don tions

,,

Nominal Concept $49.7M $53.3M $81.3M $184.3

Augmented Concept $52.5M $57.8M $84.1M $194.4=,

These costs,which were calculatedindollarsof1973 value,includ_.we-launch-base

capabilityand theequivalentpriceofdevelopment and productionfor theGFE main

engine;thecostsexcludeprime contractorfee. The methodology toderive thesecosts

used bottom-up estimatingtechniquesin which inputsof laborhours and material/

subcontractdollarswere estimatedat thelowestlevelsofthework breakdown struc-

ture(levels6 and 7 wherever possible).

The DDT&E costs are low because the Shuttle/Agena Upper Stage takes advantage of

inheritance in stage design (from the Agena vehicle), in subsystems hardware (from

ongoing LMSC and collateral programs), and in GSE and facilities (from Agena pro-

grams). A rigorous but efficient ground t,._t program, in lieu of flight testing, further

contributes to the low DDT&E cost. The breakdown of DDT&E costs is given below.

For convenience in comparing Agena costs against those stages for which just one

launch base was evaluated, the costs for ETR-only DDT&E activity associated with

the Shuttle/Agena are summarized on the bottom line.

Nominal C,mcept Augmented Concept

Project Management $ 1. 146M $ 1. 146MSystems Engineering/Integration 4.022 4. 234Vehicle Main Stage _;4.629) (26.895)

Structures 1. 643 2.042. Thermal Control 0.302 0.302

Avionics 9.469 10. 718Propulsion 7.9t0 8.55_Orbiter Interface 2.490 2.490Auxiliary Tankm 2.683 2.683Final Assembly (Tooling) 0.102 0.102

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Nominal Concept Augmented Concept

Logistics (Training} $ 1.078 $ 1.078Facilities 0.587 0. 587Gsc 5. 704 5. 704

Vehicle Test (6. 115) (6. 355)Test Hardware 3. 154 3. 236Test Operations 2. 961 3. 119

Flight Operations (Software} 6.452 6.452

. Total (ETR/WTR) $49.733M $52.451M

| ETR Only $46.533M $49.251M

; The Shuttle/Agena Upper Stage has low Production costs because it is simple in design

(single engine, earth-storable propellants) and because the core Ageaa stage has at-

mined considerable maturity in production. A breakout of the Production costs is

below. These costs cover the acquisition of a reusable vehicle fleet, Orbiter inter-

face equipment, and initial spares.


Project Management $ 1. 331M $ 1. 331MSystems Engineering/Integration 7. 794 7. 794Vehicle Main Stage (35.208) (38.826)

Structures 1.567 1. 567Thermal Control 0.345 0.345Avionics 15.162 18. 193Propulsion 7.55i 8. 141

' Orbiter Interface 2.782 2.782Auxiliary Tanks 4.045 4.045Final Assembly/Checkout _ _-_". _ ,. ,oo 3. 753

Logistics 0.840 0.840Vehicle Spares 7. 533 8.460GSE Spares 0.573 0.573

total (ETR/WTR) $53.279M $57. 824M

ETR Only $36. 379M $39.824M

Operations costs for the reusable Shuttle/Agena Upper Stage are low because this ve-

hicle exhibits high mission efficiency. That is, it can fulfill an operational mission

model with full vehicle reuse and without recourse to large numbers of kick stages.

The breakdown of Operations phase costs is presented below. These costs cover

prelaunch handling and checkout, propellants, Agena countdown, Age_a control in

flight, stage recovery and sating, and schduled/nonscheduled, maintenance (including

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spares for 93 flights 1980-1983. The costs also include main plant sustaining engineer-

ing and program management.


Project Management $1.465M $1.465MSystems Engineering/Integration 5.033 5. 033Vehicle Main Stage (Sustaining) 6.665 6.665Logistics (Transfer/HandLing/

inventory Control) 2.830 2.830GSE (Maintenance) 0.267 0.267WTR Launch Operations 1. 385 1. 385ETR Launch Operations 10.584 10.584DoD Flight Operations 5. 871 5.871NASA FLight Operations 8.162 8. 162ETR Refurbishment/Integration 11. 683 11.683WTR Refurbishment/Integration 2.446 2.446Spares, Main Stage 22.604 25. 381Spares, GSE 2.294 2.294

Total (ETR/WTR) $81. 289M $84. 066M

ETR Only $67.989 $70.266M

Funding requirements for the reusable Shuttle/Agena Upper Stage require minimum

investment in the critical years of Sjace Shuttle system development and remain

nominal in following years. The peak in total program funding for either of the Shuttle/

Agena concepts is under $40 million in fiscal years 1980 and 1981. Figure 5-17 dis-

plays the Shuttle/Agena funding requirements by fiscal year.

Costs in MilLionsI

Fiscal 77 78 79 80 81 ] 82 8" 84 TotalYear I

DDT&E

Nominal 12.7 18.4 11.6 4.3 2.1 0.5 0.1 6.7 49.7Augmented 13.8 19.7 11.9 4.4 2.1 0.5 0.1 52.5

Production

Nominal 9.9 28.7 12.8 1.9 53.3Augmented 10.7 31.2 13.9 2.0 57.8

Operations

Nominal 2.2 20.1 25.7 26.6 6.7 81.3Augmented 2.2 21.0 26.7 27.5 6.7 84.1

Total

Nominal 12.7 18.4 21.5 35.2 35.0 28.1 26.7 6.7 184.3Augmented 13.8 19.7 22.6 37.8 37.0 29.2 27.6 6.7 194.4

Fig. 5-17 Funding Requirements5-18


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The life-cycle costs of the growth Agena (for both ETR and WTR capability) may be

summarized as follows:

DDT&E (10-use life goal, 8096B engine) $104.7 M

Production 51.9

Operations (93 flights, ETR/WTR) 76.3

Total $232.9

Cost data for the drop tank Agena configuration were not developed.

5.7 ALTERNATI_E CONCEPTS

The growth and drop tankAgena configurationsshown in Fig.5-18 bothuse theBell

AircraftCorporationModel 8096B enginewith N204/MMH propellants.With a 100:1

expansionrationozzlethisenginewilldelivera specificimpulse of 326 sec (3198N

sec/kg). Concepts characteristicsand comparisons are summarized in Fig. 5-19.

Some significant comparisons of these concepts are:

• The drop tank Agena features blowdown pressurization and cascade pro-pellant feed in the SOTs to provide drop capability, while the growth stageincorporates regulated pressurization in the two main tanks. The pres-sure in the DTA core tanks is also regulated. (A parallel feed approachis also feasible for the strap on tanks of the drop tank Agena.

• The drop tank Agena uses existing core structure as_ _,mbties with new SOTsand core tanks made of 2021 aluminum. The growth stage Agena uses exist-ing aft section structure, new separate tanks made of 2021 aluminum, anda modified SCS forward rack.

• From an avionics standpoint, both stages incorporate a BUSS, redundantcommunication assemblies, automatic RCS fault isolation and fail-safecontrol, a tape recorder, and similar types of batterires; therefore thereare no significant differences except in equipment location in the forwardsection.

• The growth stage Ageaa is supported in the cargo bay by a single truss-shellstructure with doors. The drop tank Agena uses strap-on tanks supported

i in the same manner as the Agena upper stage concept, i.e., an aft truss! assembly and a forward whlffle-tree-truanion assembly (pivot capability

for readily accommodating deflections). The aft assembly also incorporatesa kit so that the core vehicle can be accommodated when it operates withoutdrop tanks.

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Item Growth Agena Drop Tank Agena

Dimensions

Length 29.9 ft (9.12 m) 28.4 ft (8.65 m)Diameter 10.0 ft (3.05 m) 12.0 ft (3.66 m)

Propellants N2OI/MMH N204/MMH

Engine I 326 sec (3195 N sec/kg) Same as Growthsp 8096B Engine = 100:1

Thrust 16,000 lbf (71,200 N) 16,000 lbf (71,200 N)

ACPS I 125 sec (1227 N sec/kg)sp 175 sec (1718 N sec/kg) Same as G"_owth Agena(N2H4) Thrust

redundant in hi mode |0.5 lbf (2.2 N) 12 lbf (53.4 N) __L

Pressurization Regulated Regulated Core, Blowdown SOT

PropellantFeed - Cascade feed from SOTsAbort Dump 100% Same as Growth

Tankage 2 Separate Tanks 2 separate core tanks + 6 dropSOT

Tank Attach Interstage Separable FWD rods and AFTcone for SOTs

Equip. Structure Modified 10 ft (3.05 m) Existing 5 ft (1.52 m) FWDSCS; existing aft section rack, AFT core and rack

Comm urdc attons RedundantGuidance & Nay. Existing IMU, modified CEA Same as Growth Agena

& HSA; Star Tracker I

included iData Mgt DF 224 computer-single

string, CIU and tape irecorder ]

Electrical (Primary) 2 Type 30 batteries

Buss Gyros, Magnetometer, |J-Box, Type IV B Battery -J

Orbitel Interface

CBSS Single truss and shell FWD and AFT assembliesw/doors

DUMP Liquid & pneamatic Same as Growth, but re-tuterface8 & retractor configured

Communications Safety hardllne; wave train, Same as GrowthRF

Display/CMDS RDM and display panel Same as Growth

Fig. 5-19 AlternativeConcepts Characteristics/ComparisonSummary

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Weights for the growth and drop tank Agena concepts are summarized in Fig. 5-20.

Drop Tank Agena

: Growth SOYItem Agena Core & Core

r

Structure 1,321 717 1,310

Propulsion 673 542 882

Avionics 788 788 807

Thermal Control 49 32 62

Contingency (10%) 283 208 306

Dry Weight, lb (kg) 3,114 2,287 3,367(1,411) (1,037) (1,527

Fig. 5-20 Drop Tank and Growth Agena Concept Weights

Performance data for growth and drop tank Agena configurations are presented in

Fig. 5-21, 5-22, and 5-23. The growth Agena is able to deliver large payloads to

earth orbital missions. This configuration is capable of performing planetary missions

when an existing kick motor (TE-364-19) is used. The expendable mode of operation is

used when large payloads are required for the high energy missions.

The 5-foot(1.52m) Shuttle/Agenais a flexibledesignbecause thecore can be used for

intermediatealtitudemissions, and when configuredwithstrap-ontankshighaltitude

missions can be performed. Ifcertainmissions requireadditionalcapability,the SOTs

can be jettisoned,inpairs, thusextendingtheperformance envelopeas shown in Fig.

5-21. Existingkick motors such as theTE-364=19 can assistthisconfigurationin

deliveringmoderate sizedpayloadstointerplanetarymissions.

PayloadConfiguration Ib (kg)

• 10 ft Full Growth Agena (N204/MMH) 3,340 (1,515)

• 5 ft Diametur Reusable Ageaa (N_Oa/MMH)• With TE-M-364-19 Kick MSto_ 1,870* (848)$ With 3 Strap-on Tank Kits 1,680 (762)

• 1 Ejectable Kit 3,005 (1,363)• 2 Ejectable Kits 4,120 (1,869)• 3 Ejectable Kits 5,240 (2,377)

• Increase_ to 2300 lb (1043 kg) with orbiter parkingorbit of 600 run (1111 kin)

Fig. 5-2l Synchronom_-Equatorial Payload Capability For N204/MMHConfigurations I = 326 Sec

sp.

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Section 6

CONCLUSIONS

The Shuttle/Agena Upper Stage interim Space Tug concepts described in this report

are characterized by low cost, operational flexibility, safety, performance well

beyond the minimum required, low development risk, and easily attained growth

options.

The relatively low Agena DDT&E cost of $49.8 M is a direct function of the minimum

modifications required to adapt the existing Agena for use as a Shuttle upper stage.

This adaptation includes compatibility with the Shuttle interface, Space Tug require-

ments and guidelines, and the eleven-year Tug mission model.

The strap-on-tank option provides propellant Ioad flexibility that directly benefits

both the Shuttle and payloads carried by the "P_g. The capability to fly with varying

propellant loads, without the usual penalty of off-loading, results in more efficient

use of each Shuttle flight and more closely tailors the Agena performance capability

to that needed by the payload for completion of its mission.

The 5-foot (1.5 m) diameter of the Agena lends itself to side-by-side packaging in

the cargo bay with 2 or 3 Agenas mated with individual spacecraft, and deployed and

flown one at a time. The payloads could be identical or there could be a mix of pay-

loads and missions.

The Agena is a safe Upper Stage for operation in and about the Space Shuttle. Positive

main propellant tank pressure control is provided by redundant automatic control of the

tank pressurization and tank vent systems. Backup manual astronaut override _ _ the

automatic control system is also provided. Positive control full propellant dump is

provided for on-pad, during ascent, or on-orbit emergency conditions. For the critical

retrieval operation fail operational/fail safe capability is provided in the form of fully

redundant commur',cations and control and attitude control. Provisions for astronaut

override by RF command is also provided through the Agena redundant communications

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Agena synchronous equatorialplacement capabilityis substantiallyhigherthanthe

required3500 pounds (1586kg)with Agena returnto theShuttleorbitforretricval

by theShuttle.

Only minimum modificationsare requiredon the Agena forcompatibilitywiththe

Shuttleand the mission model. These modificationsare confinedto minor main

enginechanges and theadditionofthe strap-on-tankoptionto provideforflexibility

in mission Avelocityneeds. The developmentriskisthereforequitelow and con-

sistentwiththeoperationalmaturityofthe Agena.

The growth capabilityofthe Agena e_tendswellbeyond thatrequiredfor I00 percent

captureofthe existingmissionmodel. This growth iseasilyachievedthrough minor

modificationofthe vehicleand operatingmodes and iswithin1973 technologylevels.

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